Hi all,
I've been working on a quad headlight design for a couple of years now, weekends mostly. Had quite a lot of issues as you may imagine. Nothing I can't deal with though.
The design has changed quite considerably in the last year. I can safely say that I'm almost there. But I need some assistance.
I'm currently after set of headlight brackets. second hand if poss. ( obviously trying to keep the costs down ).
Here's what I'm after ..... what looks like number 2 in the diagram >>
To better explain, here's a picture of an old one I took a couple of years ago ...... already modded ! >>
I'm after an 'unmolested' set, as I realise now I cut away too much :*
we do have a breakers in Jersey, but they're next to useless ! they'd probably say ...... what's a T4 ? I:
Quick rundown how things are going, if anyones interested .....
On a previous thread I posted the 'test rig' with all the wiring and switching complete. The 90mm headlamp units are by Hella.
The high beam is of reflector type and the low beam is a projector type ( switchable LHD/RHD ). In high beam all four units are on.
These things are so bright you wouldn't believe ! you can actually feel the heat off them ! >>
I had to design the mounting brackets for the units from scratch, it took literally day's just measuring. I then sent my design to be lazer cut. When I received the templates back ( 2 months later ), I was surprised to see that they had used 2mm stainless steel, instead of the 1.5mm I had requested !
Oh well, they're here now, I may as well try to fit them. I did email them, they apologised profusely, and told me they would send replacements FOC in 1.5mm.
In the meantime, I had a fitting to do. >>
When I 'married' them up, they looked OK, great .... all I got to do now is to shape the mounting tabs to fit the bulkhead.
Not so easy with 2mm stainless steel ! I wanted to use stainless steel for two reason, one; no corrosion, and two; no flexing.
There's nothing worse than poor headlights that judder when your engine is on idle. >>
As I don't have a workshop ( I don't even own a vice ! ) bending the mounting tabs was just impossible for me.
Here's the resulting 'farce' >>
So I packed up for the day, disappointed to say the least
I realised the tabs were an issue, so I asked the steel fabricator to cut all the tabs off, before sending me the 1.5mm ones, as I knew I would struggle with those as well. A few days later they arrived. Now I was in the position to mount the headlight units into the mounting frames ( as this step could not be done with the 2mm templates ..... too thick ! ).
One of the major issues had been resolved many months ago ..... how to put x2 90mm units side-by-side in the aperture provided in the bulkhead. Here's what you've got to play with >>
And here's a shot of the rear of the 90mm Hella units. And these units are quite compact ! >>
Hight beam and low beam mounted in the mounting frames, are fully adjustable >>
As bending and twisting the steel tabs is such an issue, I found a way around it. Why not mount my 'template' into the original VW mounting frames !? ...... The original idea I had over a year ago I:
Thing is, back then, I was toying with the idea of installing two 120mm units side-by-side. A designed I dropped very quickly, as it's not possible.
This is where the project has stalled >>
In the picture above you can just see the VW mounting bracket, fitted to the bulkhead.
Now I'm sure you can appreciate the need for me to get my hands on some of these brackets. Cheap as possible, as I'm going to remodel them.
Sorry to have taken so much of your time, but it's for a good cause .... I think
TURK
I've been working on a quad headlight design for a couple of years now, weekends mostly. Had quite a lot of issues as you may imagine. Nothing I can't deal with though.
The design has changed quite considerably in the last year. I can safely say that I'm almost there. But I need some assistance.
I'm currently after set of headlight brackets. second hand if poss. ( obviously trying to keep the costs down ).
Here's what I'm after ..... what looks like number 2 in the diagram >>
To better explain, here's a picture of an old one I took a couple of years ago ...... already modded ! >>
I'm after an 'unmolested' set, as I realise now I cut away too much :*
we do have a breakers in Jersey, but they're next to useless ! they'd probably say ...... what's a T4 ? I:
Quick rundown how things are going, if anyones interested .....
On a previous thread I posted the 'test rig' with all the wiring and switching complete. The 90mm headlamp units are by Hella.
The high beam is of reflector type and the low beam is a projector type ( switchable LHD/RHD ). In high beam all four units are on.
These things are so bright you wouldn't believe ! you can actually feel the heat off them ! >>
I had to design the mounting brackets for the units from scratch, it took literally day's just measuring. I then sent my design to be lazer cut. When I received the templates back ( 2 months later ), I was surprised to see that they had used 2mm stainless steel, instead of the 1.5mm I had requested !
Oh well, they're here now, I may as well try to fit them. I did email them, they apologised profusely, and told me they would send replacements FOC in 1.5mm.
In the meantime, I had a fitting to do. >>
When I 'married' them up, they looked OK, great .... all I got to do now is to shape the mounting tabs to fit the bulkhead.
Not so easy with 2mm stainless steel ! I wanted to use stainless steel for two reason, one; no corrosion, and two; no flexing.
There's nothing worse than poor headlights that judder when your engine is on idle. >>
As I don't have a workshop ( I don't even own a vice ! ) bending the mounting tabs was just impossible for me.
Here's the resulting 'farce' >>
So I packed up for the day, disappointed to say the least
I realised the tabs were an issue, so I asked the steel fabricator to cut all the tabs off, before sending me the 1.5mm ones, as I knew I would struggle with those as well. A few days later they arrived. Now I was in the position to mount the headlight units into the mounting frames ( as this step could not be done with the 2mm templates ..... too thick ! ).
One of the major issues had been resolved many months ago ..... how to put x2 90mm units side-by-side in the aperture provided in the bulkhead. Here's what you've got to play with >>
And here's a shot of the rear of the 90mm Hella units. And these units are quite compact ! >>
Hight beam and low beam mounted in the mounting frames, are fully adjustable >>
As bending and twisting the steel tabs is such an issue, I found a way around it. Why not mount my 'template' into the original VW mounting frames !? ...... The original idea I had over a year ago I:
Thing is, back then, I was toying with the idea of installing two 120mm units side-by-side. A designed I dropped very quickly, as it's not possible.
This is where the project has stalled >>
In the picture above you can just see the VW mounting bracket, fitted to the bulkhead.
Now I'm sure you can appreciate the need for me to get my hands on some of these brackets. Cheap as possible, as I'm going to remodel them.
Sorry to have taken so much of your time, but it's for a good cause .... I think
TURK